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TALAT Lecture 3210: Continuous Casting

TALAT Lecture 3210: Continuous Casting

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Published by CORE Materials
This lecture gives an overview about the possibilities to produce aluminium foilstock and wire-bar in a continuous way. Continuous casting is the preferred casting method in modern plants because it offers higher productivity. But there are limitations in the use of this technology because not all alloys can be cast. The product shows properties that can differ from conventional material. This lecture demonstrates the principal of operation; technologies for continuous casting; types of casters; areas of application; properties of the products; behaviour of the products in further processing. General knowledge in materials engineering, some knowledge about aluminium alloy constitution and heat treatment, engineering background in manufacturing processes and basic knowledge of foundry practice is assumed.
This lecture gives an overview about the possibilities to produce aluminium foilstock and wire-bar in a continuous way. Continuous casting is the preferred casting method in modern plants because it offers higher productivity. But there are limitations in the use of this technology because not all alloys can be cast. The product shows properties that can differ from conventional material. This lecture demonstrates the principal of operation; technologies for continuous casting; types of casters; areas of application; properties of the products; behaviour of the products in further processing. General knowledge in materials engineering, some knowledge about aluminium alloy constitution and heat treatment, engineering background in manufacturing processes and basic knowledge of foundry practice is assumed.

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TALAT 3210
TALAT Lecture 3210
Continuous casting of aluminium
27 pages, 23 figures
Basic Level
prepared by Dr. \u2013Ing. Catrin Kammer, Goslar
Objectives:

This chapter gives an overview about the possibilities to produce aluminium foilstock and wire-bar in a continuous way. Continuous casting is the preferred casting method in modern plants because it offers higher productivity. But there are limitations in the use of this technology because not all alloys can be cast. The product show properties that can differ from conventional material.

The chapter will show
- the principal of operation
- technologies for continuous casting
- types of casters
- areas of application
- properties of the products
- behaviour of the products in further processing

Prerequisites:

- General knowledge in materials engineering
- Some knowledge about aluminium alloy constitution and heat treatment
- Engineering background in manufacturing processes
- Basic knowledge of foundry practice

Date of issue 1999
\u00a9 European Aluminium association
TALAT 3210
2
3210 Continuous casting of Aluminium
Contents
3210 Continuous casting of Aluminium..........................................................................2

3210.01 Introduction................................................................................................. 3 3210.02 Strip casting................................................................................................3 3210.03 Wire bar casting.......................................................................................... 5 3210.04 Distinguishing features of continuous casting technologies.................... 6 3210.05 Twin drum casters...................................................................................... 9

3210.05.01 Vertical casting direction......................................................................9
a) Vertical downward - Hazelett Sr. (1930 \u2013 1940)............................................ 9
b) Vertical upward - Hunter Engineering........................................................... 9
3210.05.02 Casters with horizontal casting direction............................................10

a) Scal, Alusuisse I, Jumbo 3C.......................................................................... 10 b) The development of the Jumbo 3C to the Jumbo 3CM thin roll caster........ 12 c) Casting direction at an angle - The FATA Hunter SpeedCaster.................. 13

3210.06 Single drum casters................................................................................... 14
3210.07 Block casters.............................................................................................. 15
3210.07.01 Hunter-Douglas (Block caster)...........................................................15
3210.07.02 Alusuisse Caster II..............................................................................16
3210.08 Belt casting techniques............................................................................. 16
3210.08.01 Hazelett Caster....................................................................................16
3210.08.02 Kaiser Caster.......................................................................................17
3210.09 Casters with a combination of a rotating steel belt and a water-cooled
casting wheel............................................................................................................ 19
3210.09.01 Properzi-Caster...................................................................................19
3210.09.02 The Rigamonti and the Rotary Caster.................................................20

3210.10 Structure and properties of strip castings.............................................. 20
3210.11 Behaviour of strip castings in further processing (rolling, thermal
treatment)................................................................................................................ 22

3210.11.01 Cold rolling.........................................................................................22 3210.11.02 Deep drawing......................................................................................24 3210.11.03 Recrystallization.................................................................................24

3210.12 Literature................................................................................................... 26
3210.13 List of Figures............................................................................................ 27
TALAT 3210
3
3210.01 Introduction

Due to its many economic advantages the continuous casting of aluminium has become more and more important during the last 40 years. These processes are mostly used for the production of a semifabricated strip, for cold rolling to foilstock building sheet and canstock. They are also used to cast endless wire bar stock.

Continuous casting processes converts molten aluminium alloys directly into an endless coiled strip suitable for cold rolling or wire-bars for wire-drawing. They effectively eliminate the operations associated with traditional mould casting (discontinuous process) or D.C. casting (a semicontinuous process) and subsequent hot mill deformation. Therefore the capital investment and operational costs are significantly lower than in a conventional production process. Continuous casting is the preferred casting method in many modern plants because it offers higher productivity. Continuous casting has been employed with increasing commercial success for aluminium as well as other metals.

Among the continuous casting technologies the strip casting processes now account for a remarkable share of the worlds output of rolled aluminium semifabricated coilstock (approximately 30%).

While strip casting will be the main topic of this chapter, the technology for the production of wire bar will also be described. Semicontinuous processes (DC casting) are discussed in Lecture 1301.

3210.02 Strip casting

Continuous strip casting has proved itself for the production of foilstock, of strip for painting and \u2013 in some cases \u2013 of strip for deep drawing processes. The various strip casting technologies are suitable for the casting of wrought alloys and allow the production of strip from 3 mm to 20 mm thickness and up to 2150 mm width.

Figure 3210.02.01 illustrates the main feature of all continuous casting processes.
Molten metal enters the casting mould (in Figure 3210.02.01, the space between two
rolls), solidifies there and leaves the mould as a continuous strip.

After casting the strip can be directly coiled \u2013 or it can be immediately (without down cooling) rolled into a coilable gauge. For the mass production of collapsible tubes and rigid cans the machines for the blanking of slugs or for extruding can be placed directly after the casting machines. In this way a continuous production is achieved.

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